Roof Repair Composition and Method for Repairing Roof Shingles

ABSTRACT

The present invention relates to a method for repairing a shingle roof comprising the steps of providing a base aqueous medium selected from the group consisting of urethane, polyurethane, wax particulates dispersed in water, and butyl ether, and mixtures thereof; providing additives selected from the group consisting of sand, silica, polymer particles, plastic fibers, and fiberglass fibers, and mixtures thereof, applying the aqueous medium to a shingle roof, forming a first layer, applying the additives to the first layer, and drying the layers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a nonprovisional of, and claims the benefit of, U.S.Patent Application Ser. No. 61/792,111, filed Mar. 15, 2013, which isentitled “Roof Repair Composition and Method for Repairing RoofShingles.”

BACKGROUND OF THE INVENTION

This invention relates to a composition and method of use for repairingasphalt shingles in residential roofs using a urethane and/or waxcomposition dispersed in water.

Residential roofs are exposed to the elements, including rain, snow,ice, and wind. Roofs will wear in response to the elements and it is notuncommon for a house to experience roof shingle damage due to any ofthese elements. This often will be apparent via leaking or water damage.As this occurs during the winter months, roofing shingles areintermittently covered with snow and ice, and until the season ends, itis difficult to perform maintenance, or complete roofrepair/replacement. In response, it is desirable to have a way ofrepairing damage that could be implemented during the brief periods whenthere is no snow or ice on the damaged shingles and the outside airtemperature is higher; have minimal cosmetic changes to the existingroof; and could be applied to a large area in a short period of timewithout standing on damaged shingles.

As a residential asphalt (bitumen) shingled roof ages, the shinglematerial hardens. This hardening makes the shingles more brittle.Shingles become susceptible to cracking, which can lead to waterinfiltration, which leads to roof leaks. Specifically, small cracks, ifnot repaired, allow ice to form in the cracks, and the cracks can becomelarger due to the environmental influences. On older roofs, the weightof the repairer traversing or standing on brittle shingles whilerepairing the damaged shingles can cause further cracking or damage toshingles, or can cause damage to shingles that originally had no damage.It is apparent that a method of repair which eliminates or reduces thenecessity of the repairer being on the roof is advantageous.

A number of patents and publications offer various repair solutions. Forexample, U.S. patent publication 2012/0322913 to Fontenot, III et al.,teaches a durable substrate coating and process which can be applied asa liquid over an existing roof. Japanese patent publicationJP2012251094A, teaches a low pollution, high weather resistance coatingor coatings that are applied to the outer wall of a building as a repairwater-based coating composition. U.S. Pat. No. 6,001,906 to Golumbic,teaches a coating which is a combination of polyurethane and wax for usein providing a coating for leather and vinyl materials. U.S. Pat. No.4,661,532 to Morin, teaches a hydrophobic foaming polyurethanecomposition repair composition containing two substrates (one of whichcontains coal tar) which are mixed at time of application to hard,rigid, foam mass to repair surface defects. U.S. Pat. No. 4,576,987 toCrockatt et al., teaches aqueous water-repellant coatings that areprimarily intended for exterior wood surfaces, using a large proportionof paraffin wax for sealing and finely divided silica to hold theparticles in stable suspension. U.S. Pat. No. 4,390,678 to LaBelle etal., teaches a one package heat curable polyurethane composition usefulfor adhesive bonding of similar and dissimilar materials, an injectionmolding compound and for sheet molding repair of fiberglass.

Product literature for TK-9030, manufactured by: TK Products. Divisionof Sierra Corporation Crack Repair teaches a low viscosityurethane/polyurea hybrid. For use as a low viscosity sealant for deepcrack repair of bridge decks and concrete slabs. Product literature forFASTENAL® GEOCEL®, manufactured by GEOCEL Corp., teaches a polyurethaneroof tile adhesive/sealant used as a one part roof tile adhesive sealantused in the application of roof tile, valley tile, wall tile or brokentile.

SUMMARY OF THE INVENTION

The present invention relates to a method for repairing a shingle roofcomprising the steps of providing a base aqueous medium selected fromthe group consisting of urethane, polyurethane, wax particulatesdispersed in water, and butyl ether, and mixtures thereof; providingadditives selected from the group consisting of sand, silica, polymerparticles, plastic fibers, and fiberglass fibers, and mixtures thereof,applying the aqueous medium to a shingle roof, forming a first layer,applying the additives to the first layer, and drying the layers. Thecoating composition can also include suspended color pigment insolution.

DETAILED DESCRIPTION OF THE INVENTION

The present invention generally relates to a composition and method ofuse for repairing asphalt shingles in residential roofs. Specifically,it is a coating composition consisting of a base aqueous medium of 1)urethane 2) polyurethane and/or 3) wax composition dispersed in water.It can further include alkyd polymer, butyl ethers, (butoxyethanol,specifically 2-butoxyethanol), and paraffin wax. This invention includesa method of protecting the surface of a substrate, comprising: (1)applying to the surface a thin coating of a non-toxic, water-based,colloidal coating composition, and (2) drying the coating to evaporatethe water, so that a tough, durable film is formed on the surface whichis bonded firmly to said surface. Silica (sand) may be added to theaqueous medium to enhance the sealing of small cracks. Flat shreddedplastic particulates or light aggregates may be added to the materialsurface between applications of chemical media to aid in the sealing oflarger cracks. The sand and other additives will be discussed in greaterdetail below, following the discussion of the chemical components(polyurethane, wax, etc.). The aqueous medium dries rapidly to form adurable film.

The present invention achieves long term repairs, with minimal cosmeticimpact. It attempts to increase the life of mature residential roofs,saving natural resources used in the manufacture of new shingled roofs.Current residential roofs, using shingles, require material andtime-intensive process(es) to repair shingles. The present inventionattempts to repair damage ranging between minor to more severe shingledamage using non-invasive repair techniques, with reduced repair timeand without shingle replacement. This repair mechanism is to be appliedto a large area in a short period of time. Further, roof repairpersonnel, preferably, should not need to be on the roof to facilitaterepair. This enhances personnel safety and reduces the possibility offurther cracking and other physical damage to shingles, and/or avoidsdamage to previously undamaged shingles.

The chemical media of the invention serve as a transport mechanism forwax particles or urethane to the shingle surfaces and cracks. They maysoften older, brittle shingles, allowing better adhesion of paraffin waxparticulates or urethane. Application can be accomplished via paintsprayer, paint roller, paint brush, sponge, or pouring. Roof repairpersonnel do not need to be on the roof to facilitate repair.

Color/pigmentation can be added to help blend the color of the repairmedia to the existing roof shingles. This can also be used todifferentiate the color of the repaired area versus surrounding shinglesto prevent workers/contractors from traversing on the repaired area.

Particulate sand is added to the aqueous medium prior to application toenhance the sealing of small cracks. Flat shredded plastic particulatesor light aggregates are manually applied to the material surface betweenapplications of chemical media to aid in the sealing of larger cracks.

With respect to the coating, this invention uses water as the carryingagent or medium for the film forming material, and thereby avoids theproblems associated with hydrocarbon based coatings. Moreover, a resin,or mixture of resins, is used as the film forming material which has theproper flexibility and abrasion resistance for the applicationpreferably without the need for inclusion of plasticizers into thecoating. For example, a coating applied to asphalt shingles in snowyareas must be more durable and tougher than one applied to a roof in awarmer climate, but plasticizers can be used to improve durability.Flexibility and abrasion resistance are inversely related, such that anincrease in flexibility results in a decrease in abrasion resistance,and vice versa Roofing shingles can be bent to conform to shapes. Likematerials in general, bending of the shingles past their ‘elastic limit’can result in fine cracks in the shingles, affecting their waterproofingand abrasion properties. As used herein, the term “plasticizer” means anadditive that makes a coating or material more plastic or moldable; itcan impregnate or coat something, usually to make it waterproof.Moldability softens the parent material, thereby affecting durability.The primary goal of this invention is not to soften, or make the baseshingle more moldable, but to provide a coating. Plasticizers can alsobe applied to the surface for waterproofing.

The coating composition of the present invention has several features,no single one of which is solely responsible for its desirableattributes. Without limiting the scope of this invention as expressed bythe claims which follow, its more prominent features will now bediscussed briefly. After considering this discussion, one willunderstand how the features of this invention provide its advantages,which include high impact and abrasion resistance, excellent elongationand flexibility, outstanding stain and chemical resistance, early filmintegrity, fast dry-to-handle properties, air drying, outstandingtoughness, excellent adhesion to heat- and solvent-sensitive substrates,compatible with anionic pigments and dispersing agents, water thinnable,suitable for white and light pastel shades, usable as primer andtopcoat, stable to repeated freeze/thaw cycles, low solvent content,non-flammable, water clean-up, creates a high heat resistance barrier,high gloss, if desired, and is non-toxic and safe to use.

After evaporation of the water carrying agent, the polyurethane and waxcombine to form a tough film bonded to the surface of the substrate towhich the coating composition is applied. The coating, in someinstances, is absorbed by asphalt substrates, and this tends to improvethe bond between the film and the substrate.

The composition may be clear or pigmented, that is, transparent,translucent or opaque. A major portion of solids present in thecomposition are polyurethane and a minor portion of solids present inthe composition are wax. It is believed that the polyurethane and waxinteract synergistically to provide a barrier for a substrate whichunexpectedly has a high heat and abrasion resistance. The film formedon, for example, asphalt shingles, creates a high heat resistantbarrier. The film without flattening agents has a high gloss. Thiscombination of polyurethane, wax and other additives and processes aremainly responsible for the desirable attributes of this invention.

The composition is applied as a coating to the surface of a substrate,and dries rapidly in air at ambient temperatures of about 40° F.-90° F.,and 50% or less relative humidity. High relative humidity will increasethe drying time of the material, increasing the time span betweenapplications of different coats of material. As this is a liquid basedmedium, it must have adequate time to permeate the shingle substrate,filling any cracks in the surface, to form a tough, durable film that isbonded firmly to the surface. High temperatures will cause the liquidbarrier to evaporate faster, reducing the permeation of the shinglesubstrate. In cold temperatures or high humidity conditions, hot air maybe used to speed the rate of drying. This can be accomplished using anymeans known in the art, including but not limited to, heat guns, hairdryers, and fans, for example. The composition can be self-drying, suchthat it dries in ambient temperatures and no additional drying means arerequired. The composition may be used to coat such materials as, forexample, asphalt shingles, leather, vinyl polymers, flexible andsemi-rigid plastics, rubber, polycarbonate, reaction-injection moldingcompound, thermoplastic polyurethane, acrylonitrile-butadiene-styrene,wood, aluminum, and galvanized metal. The preferred use is on asphaltshingles.

A polyurethane colloid is used as the principal ingredient of thecomposition of this invention. One of the desirable features of thepolyurethane used in this invention is that it forms a flexible film. Acharacteristic of the polyurethane film is that it has a percentelongation in the range between about 150 and about 700. Although anaromatic polymer may be used, the film tends to yellow or darken overtime, and consequently, an aromatic polymer is unsuitable when a clear,transparent film is desired. The particles of polyurethane vary widelyin size, but the major portion range between about 200 and about 800microns.

Other ingredients may include co-solvents, flattening agents, rheologycontrol compounds, mar resistant additives such as a silicone polymer ora fluorocarbon polymer, acrylic resins, and dyes or pigments. Theco-solvents extend drying times, which may be desirable in someapplications, and improve substrate wetting.

Since the film will be exposed for prolonged periods of time tosunlight, it will be desirable to blend with the composition ultravioletlight stabilizers. However, the composition can be formulated to beessentially free of ultraviolet light stabilizers as separate additives.

As noted above, this invention includes additional additives to aid inthe repair of damaged shingles. Introduction of particulate sand into ahomogenous solution of the chemical medium aids in sealing cracks inworn shingles. The sand consists of clean, hard, uncoated grains, freefrom organic matter, alkali, and vegetable matter. The present inventionfunctions to repair small to medium size cracks, which commerciallyavailable aqueous media did not effectively seal or repair. Additionalparticulate material was needed, which in the homogenous state, aided insealing small to medium cracks. Sand is used due to its abundance innature, variable particulate size and minimal environmental impact. Whena spray gun is used to apply the product, the maximum particulate sizeis regulated by the nozzle opening size of spray gun. The particulatesize should pass through a #30 sieve (0.0154 inch wire diameter) orsmaller. The amount of sand added to mixture should be 0 to 10% ofmixture volume. Mixture volume can be increased, but due to theresultant thicker consistency of the medium, use of spray equipment maynot be possible. When the medium is applied using a brush, paint brushor sponge, larger particulate sizes can be used. This particulate sizecan pass through a sieve size 100 (0.0043 wire diameter) or larger wirediameter. The sand can be added to aqueous medium at the time ofmanufacture of the medium, or added to the medium at job site prior toapplication(s).

In addition to sand, introduction of a layer of lightweight aggregates,flat shredded plastic particulates, added between applications ofcoating composition aids in the sealing of cracks in worn shingles. Thisis used to repair larger cracks since the flat plastic particulatesclose larger cracks. The chemical medium cements the plasticparticulates in position.

These lightweight aggregates should be clean, hard, uncoated grains,free from organic matter, alkali, and vegetable matter. They should passthrough a sieve size 4 (0.060 inches) up to ⅛″ in size. They can beintroduced as a thin layer between applications of coating compositionto aid in the sealing of larger holes and cracks in worn shingles.Larger plastic additives can be used. These would be roughly thumbnailsized, clear or colored, made from thin gauge plastic sheets. This couldinvolve recycling existing plastic sheets, or virgin material.

When applying a second, or multiple coats, the prior coat must beallowed to partially dry until it is tacky to the touch. If the coatcompletely dries, that is, dries until it is dry/smooth to the touch,with no tackiness, subsequent layers will have difficulty bonding to theearlier layer(s), or not bond at all.

Use of commercially available asphalt-saturated fiberglass mesh can alsobe applied between the applications of coating compositions. This willprovide a uniform matrix for silica and light aggregates to adhere. Useof color additives to second coating of composition may reduce colorvariations with surrounding unrepaired shingles. Use of mesh will havetexture differentiations between repaired and surrounding shingles. Anexample of commercially available asphalt-saturated fiberglass mesh isHENRY® 181—black asphalt saturated glass fabric, manufactured by HenryCompany. 2911 Slauson Ave. Huntington Park, Calif. 90255.

As noted above, color pigmentation can be added to the invention. Thiscan be done by the medium supplier at time of purchase to approximatepigmentation of surrounding shingles or to differentiate pigmentation ofrepair area versus surrounding area. Alternatively, liquid pigment canbe added to base aqueous medium at the job site. Composition of pigmentto medium can be established to match the color of existing shingles, orcolored to contrast or differentiate repair area versus surroundingarea. This can blend the color of the repair media to the existing roofshingles to help ‘mask’ the repair, or differentiate the color of therepaired area versus surrounding shingles to prevent workers/contractorsfrom traversing on the repaired area. An example of commerciallyavailable color pigment is QUIKRETE® liquid cement color, inred/charcoal.

Precautions must be used in application of chemical media to preventenvironmental damage. Run-off and overspray of the chemical medium mustbe controlled.

Current commercially available roof repair media have a viscosity levelthat can make application difficult. Flow is difficult due to the highto medium viscosities of the repair media. Such repair media with highviscosity must be applied by trowel. The installer must be directly onroof to apply. Lower viscosity repair media can be poured directly ontothe roofing surface. Using such a pouring method is only recommended forflat roof repairs and not recommended for roof surfaces with a pitch.Personnel must be in close proximity to repair area to apply the medium.Chemical media of the present invention uses media having a range ofviscosities, which permit application of repair composition via paintsprayer, paint roller, paint brush, brushes, and/or sponge. Examples ofviscosities: High viscosity—material is thick, mud-like; application isby trowel and brush. Medium viscosity: material is thick, but can bepoured, but is still too thick to be sprayed. Thick and medium viscosityrepair media require longer cure times after application due to thedensity of the media. By using commercially available extension rods,range of application can be increased so it may not be necessary forpersonnel to be on the roof for application.

With proper repair process, roofing repair described in the presentinvention will not have adverse environmental consequences. The repairmechanism identified herein will not seal direct openings betweenroofing shingles through roof underlayment, for example, if branch fallsthrough roof.

The following examples provide a further understanding of thecompositions of the inventions and include a best mode. As used herein,“Light” duty repair comprises repairs to pinholes 0.0″ to 1/32″; cracksup to 1/32″ wide and less than or equal to ½″ long. “Moderate” dutyrepair comprises repairs to pinholes greater than 1/32″ diameter andless than or equal to 1/16″ diameter; cracks greater than 1/32″ wide andless than or equal to 1/16″ wide and less than or equal to ½″ long.

Example I Light Roofing Repair Needed

Select urethane or water based paraffin medium. Color pigmentationmedium can be added to medium by supplier. Mix color to either matchexisting surrounding shingles to ‘mask’ the repair area or add color to‘differentiate’ repair area (for example ‘red’). To visually alert thehomeowner or contractors of the repair area.

Clean roofing surface to remove any dirt, grime. Apply absorbentmaterial (cloth, paper) in gutters under repair area to absorb anyoverflow or overspray of aqueous medium. Discard used materials usingsame process as directed by manufacturer.

Add sand to mixture. 0% to 10% of mixture volume. If mixture is to besprayed, in order to prevent clogging, ensure that sand particulate sizeis less than orifice size of spray mechanism and decrease volume of sandto mixture. Larger sand particulate size and mixture percentage (up to10%) can be used if mixture is to be brushed, rolled or sponged ontosurface. Increasing the ratio of sand to the base media beyond thislimit can reduce the adhesive properties of the resins and/or paraffinto the roofing surface.

If color pigmentation has not been added to medium, add liquidpigmentation per instructions above. Follow color pigmentationmanufacturers instructions.

Weather: Preferred temperature range 50° F. through 90° F. Relativehumidity up to 50%. Do not apply if lower than 40° F., or if rain isexpected within 24 hours. Apply medium liberally. Spray mechanism can beused, watching overspray. Commercially available extensions can be usedwith paint brush, roller, brush, sponge to increase range ofapplication. So it may not be necessary to be on roof to apply medium.

Testing has shown that best results are obtained if a second coating isused and applied within two hours. After the second coating is appliedand while this coat is still moist, a light coating of silica sand orlight aggregate can be applied. This will impart roughness to thesurface of the repaired shingles, in contrast to the smoother surfacetexture provided by the urethane and/or polyurethane coat(s). Thissurface roughness will slow the rate of water run-off from the roof tothe gutters, more closely approximating the run-off rate of surroundingshingles.

Example II Moderate Roofing Repair Needed

In addition to all steps identified in example I above, the followingsteps are added:

After application of the first coating of the medium, add a layer offlat shredded plastic particulates, to aide in the sealing of cracks inworn shingles. Thumbnail sized plastic particulates can be clear or havecolor pigment. Plastic particulates can lay on the surface of the mediumor can be pressed into the medium with a brush or roller. Flat plasticparticulates close larger cracks. Chemical medium cements the plasticparticulates in position. Apply second coating (or more—a plurality ofcoatings) of chemical medium. Apply a coating of silica sand or lightaggregate

Example III Moderate Roofing Repair Needed

In addition to all steps identified in example I above, the followingsteps are added:

After application of the first coating of the medium, add a layer oflightweight aggregates, to aide in the sealing of cracks in wornshingles. Lightweight aggregates close larger cracks. Chemical mediumcements the aggregates in position. Apply second coating of chemicalmedium. Apply a coating of silica sand or light aggregate

Example IV Moderate to Severe Roofing Repair Needed

In addition to all steps identified in example I above, the followingsteps are added:

After application of the first coating of the medium, add a layer ofasphalt-saturated fiberglass mesh. This will provide a uniform matrixfor silica and light aggregates to adhere. Apply a layer of lightweightaggregates as identified in example III. Apply second coating ofchemical medium. Apply a coating of silica sand or light aggregate

Example of commercially available medium: SHERWIN WILLIAMS®,DECKSCAPES®. Exterior deck stain. Advanced waterborne formula. Clearsealer. 6403-59287. The Sherwin Williams Company. Cleveland, Ohio 44115

Example of commercially available medium: BEHR®, Water Proofing WoodProtector. Natural. No. 300. BEHR Process Corporation. Santa Anna,Calif. 92704. www.behr.com.

Example of commercially available medium: HELMSMAN®, MINWAX®.Indoor/outdoor spar urethane. Water based. Clear gloss. MINMAX Company.Upper Saddle River, N.J. 07458.

This invention also includes the product coated with the composition ofthis invention. Such product comprises a substrate having a surfacecovered by a solid, thin barrier which adheres firmly to the surface andis formed upon evaporation of water after the application of anon-toxic, water-based, colloidal coating composition including athermoplastic, elastomeric polyurethane and wax dispersible in water.The film has a thickness ranging between about 5 and about 100 microns.

Although the invention has been described in detail with reference toparticular examples and embodiments, the examples and embodimentscontained herein are merely illustrative and are not an exhaustive list.Variations and modifications of the present invention will readily occurto those skilled in the art. The present invention includes all suchmodifications and equivalents. The claims alone are intended to setforth the limits of the present invention.

What is claimed is:
 1. A method for repairing a shingle roof comprisingthe steps of: providing a base aqueous medium selected from the groupconsisting of urethane, polyurethane, wax particulates dispersed inwater, and butyl ether, and mixtures thereof; providing additivesselected from the group consisting of sand, silica, polymer particles,plastic fibers, and fiberglass fibers, and mixtures thereof, applyingsaid aqueous medium to a shingle roof, forming a first layer, applyingsaid additives to said first layer, and drying said layers.
 2. Themethod of claim 1 further comprising applying additional said aqueousmedium, forming a plurality of layers and applying additional saidadditives to said plurality of layers.
 3. The method of claim 1 whereinsaid wax particulates are paraffin wax.
 4. The method of claim 1 whereinsaid butyl ether is 2-butoxyethanol.
 5. The method of claim 1 whereinsaid additives comprise sand in amount 0-10% by volume of the aqueousmedium.
 6. The method of claim 1 wherein the aqueous medium is appliedusing a means selected from sprayed on, rolled on, brushed on, spongedon, poured on, and combinations thereof.
 7. The method of claim 1wherein drying said layers is done using a means selected from fan, hairdryer, heat gun, and self-drying, and combinations thereof.
 8. A shinglecomprising a substrate having a surface covered by a solid, thin barrierthat adheres firmly to the surface and is formed upon evaporation ofwater after the application of a non-toxic, water-based, colloidalcoating composition including a thermoplastic, elastomeric polyurethaneand wax dispersible in water, wherein said film has a thickness rangingbetween about 5 and about 100 microns.